[0001] The present invention relates to a power train for an electric vehicle, including
an inverter which converts a DC voltage from a battery to an AC voltage supplied to
AC motors for driving wheels of the electric vehicle.
[0002] Fig. 1 shows the main circuit of an electric vehicle. The electric vehicle employs
a battery as a power supply and an inverter as a DC-to-AC converter, and its wheels
are driven by AC motors which are supplied with AC power from the inverter. In this
figure, reference numeral 1 designates a main battery; 2, an inverter; and 3, an AC
motor for driving a wheel or wheels. The inverter 2 is a three-phase inverter, and
comprises six arms, each of which includes a transistor 201 and a diode 202 connected
in antiparallel fashion as shown in this figure.
[0003] A smoothing capacitor 4 is connected in parallel with the battery 1 between the battery
1 and the inverter 2. The smoothing capacitor 4 prevents higher harmonics, which are
included in the input current to the inverter 2, from entering the main battery 1.
In addition, it limits overvoltages induced by the switching operations of the semiconductor
switches of the inverter 2.
[0004] The power train of a conventional electric vehicle usually employs a bipolar transistor
as the transistors 201 of the inverter 2, and an induction motor as the motor 3. This
is because they will simplify the structure, reduce the cost, and facilitate employing
the conventional technology.
[0005] One of the important evaluation items of the electric vehicle is the system efficiency.
It corresponds to the fuel cost of an internal combustion engine car. This system
efficiency has great influence on the mileage (range) between charging.
[0006] In the electric vehicle, as in the gasoline car, the output of the motor at a constant
speed traveling is small as about a fraction of the maximum output. In addition, the
duration of the constant speed drive is long. Accordingly, the system efficiency of
the electric vehicle can be increased greatly by improving the efficiency in the low
output operation mode. The components in the main circuit that govern the system efficiency
are the motor and inverter. In view of this, the efficiency of the inverter will be
considered below.
[0007] A large part of the loss produced by the inverter is the loss in the power semiconductor
switching devices constituting the inverter. This loss is the sum of the stationary
loss P
sd and the switching loss P
sw. The stationary loss P
sd is produced by the current flowing through the power semiconductor switching devices
and is expressed by equation (1).

where i is the current flowing through the power switching devices, and v
d is the on-state voltage across the power switching devices, which is determined by
the characteristics inherent in the power switching devices. The power switching devices
conventionally used are bipolar transistors whose characteristics are schematically
illustrated in Fig. 2. More specifically, this type of power switching device has
a voltage v
d0 at the current of zero, and the on state voltage v
d gradually increases with the current.
[0008] Next, the switching loss will be explained.
[0009] Figs. 3 and 4 show typical switching operations of the power semiconductor switching
devices of the inverter: Fig. 3 illustrates the switch on operation; and Fig. 4 illustrates
the switch off operation. In these figures, v is a voltage across a power switching
device, i is a current flowing through the power switching device, and p designates
a waveform of the power loss in the power switching device.
[0010] Here, the switching loss P
sw is expressed by the following expression.

where t
s is a switching time, and f
s is a switching frequency. Equation (2) holds true for both switch on and off operations.
[0011] Next, the inverter loss in the conventional system is considered.
[0012] From equation (1), it is seen that the stationary loss is approximately proportional
to the current flowing through the power semiconductor switching device. This shows
that the stationary loss of the inverter is proportional to the output current of
the inverter, that is, to the input current to the motor. From equation (2), it is
found that the switching loss is proportional to the main battery voltage and the
input current to the motor because V
0 is nearly equal to the main battery voltage and f
s is approximately constant.
[0013] As the motors for driving the electric vehicle, induction motors are commonly employed.
In the induction motor, the exciting current must be supplied from the motor current.
[0014] Fig. 5 shows an example of conventional high efficiency control of an induction motor,
and illustrates the relationships between the output of the motor and the voltage
V
M and current I
M of the motor. This graph shows a method wherein the power factor of the motor are
maintained approximately constant throughout the operation range of the motor.
[0015] However, since the exciting current is also required in the low output operation
mode even in this method, the motor current I
M is not proportional to the output (a proportional line is indicated by a dotted line).
As a result, the efficiency of the motor reduces as the output of the motor decreases
because the inverter loss is approximately proportional to the output current. In
other words, the reduction in the efficiency might be prevented if the motor current
had the characteristics as shown by the dotted line.
[0016] Next, let us consider the power train of an electric vehicle to which the inverter
in accordance with the present invention is applied.
[0017] Fig. 6 is a conventional power train of an electric vehicle. The system employs a
main battery, a semiconductor power converter like an inverter, and a motor in place
of an engine and a transmission of an internal combustion engine car, and is one of
the most widely used power train.
[0018] In this figure, reference numeral 1 designates a battery, a block 8 enclosed by dotted
lines is a drive portion of the electric vehicle corresponding to the engine and transmission
of an internal combustion engine car. The drive portion 8 comprises a semiconductor
power converter 81 such as an inverter, a motor 83 such as a three-phase induction
motor, and a reduction gear 84. The reduction gear may have either a constant or a
variable reduction gear ratio.
[0019] The power converter 81 is connected, on the one hand, to the main battery 1 via DC
connecting wires 12 and a main switch, and on the other hand, to the motor 83 via
AC connecting wires 85.
[0020] The motor 83 is joined to the reduction gear 84 with a shaft 86, which might be replaced
by the output shaft of the motor. The output shaft 87 of the reduction gear 84 transmits
the output power to a differential gear 5 via universal joints 31 and 32 and a propeller
shaft 9. The differential gear 5, which is similar to that of an internal combustion
engine car, transmits the power from the drive portion 8 to right and left wheels
61 and 62 via a known differential mechanism and driving axles 71 and 72.
[0021] Fig. 7 shows another conventional power train. The power train in Fig. 7 differs
from that of Fig. 6 in that it does not comprise the differential gear.
[0022] In Fig. 7, the power train of the right wheel 61 comprises DC connecting wires 121,
a power converter 811, AC connecting wires 851, a motor 831, a coupling shaft 861,
a reduction gear 841, the output shaft 871 of the reduction gear, a universal joint
311 and the right wheel 61. This system corresponds to that of Fig. 6 comprising the
DC connecting wires 12, the power converter 81, the AC connecting wires 85, the motor
83, the shaft 86, the reduction gear 84, the output shaft 87 of the reduction gear,
and the universal joint 31.
[0023] Likewise, the power train of the left wheel 62 of Fig. 7 comprises DC connecting
wires 122, a power converter 812, AC connecting wires 852, a motor 832, a coupling
shaft 862, a reduction gear 842, the output shaft 872 of the reduction gear, a universal
joint 312 and the left wheel 61.
[0024] In Fig. 7, a function corresponding to that of the differential mechanism of the
differential gear 5 in Fig. 6 is implemented by separately controlling the torque
and the rotation rate of the respective motors 831 and 832.
[0025] Fig. 8 illustrates a power train which directly drives the wheels without interposing
reduction gears.
[0026] In Fig. 8, the power train for the front right wheel 63 comprises DC wires 123, a
power converter 813, AC connecting wires 853, a motor 833, and the front right wheel
63. Here, the motor 833 is usually installed in the rim of the wheel 63. Power trains
of the front left wheel, rear right wheel, and rear left wheel are similarly arranged.
In Fig. 8, reference numerals 124, 125 and 126 denote DC connecting wires; 814, 815
and 816, power converters; 854, 855 and 856, AC connecting wires; and 834, 835 and
836, motors.
[0027] The power train shown in Fig. 6 has such a construction as the engine of an internal
combustion engine car is replaced with the inverter and the motor. Therefore, it does
not constitute an optimum power train for an electric vehicle, although traveling
performance except for a mileage may be better than an internal combustion engine
car.
[0028] As a result, it is difficult to achieve a power train (1) of small size and light
weight, (2) of low cost, (3) of low noise, and (4) having traveling performance comparable
to that of an internal combustion engine car.
[0029] On the other hand, in the power trains as shown in Figs. 7 and 8, since the increasing
number of components of the power train is required in comparison with that of Fig.
6, the cost of the system will increase, which presents a new problem. In addition,
since the right and left wheels must be separately controlled to achieve the traveling
performance with a differential function, the controlling system becomes more complex
than that of Fig. 6, and the detection function of faults and protective measures
against those faults are needed.
[0030] Moreover, since the AC connecting wires, which are provided for connecting the power
converters to the motors in Figs. 7 and 8, generate electromagnetic noise. This also
poses a new problem accompanying the reduction of the noise.
[0031] As described above, the conventional inverter system presents the following problems:
(1) Since bipolar transistors are used as the power semiconductor switching devices,
the ON state voltage of the devices in a low current range cannot be reduced below
a certain value. As a result, there is a certain limit in reducing the stationary
loss in a low output range of the motor operation.
(2) Since the input voltage to the inverter is a main battery voltage, it is fixed.
Consequently, reduction of the switching loss in the low output operation mode of
the motor operation is also restricted.
[0032] In PROCEEDINGS OF THE 30th ANNUAL CONFERENCE OF THE IEEE VEHICULAR TECHNOLOGY SOCIETY,
September 1980, Dearborn Michigan, pages 1 to 7, Steven Geppert: "AC propulsion system
for an electric vehicle", a power train for an electric vehicle in accordance with
the pre-characterizing part of claim 1 is disclosed. The known power train comprises
an AC motor which is coupled, via a chain reduction, to a two-speed planetary gear
the output of which is connected, via final drive gears, to a differential and axle
U-joints.
[0033] IEEE TRANSACTIONS OF INDUSTRY APPLICATIONS, Vol. 1A-17, No. 5, September 1981, New
York US, pages 518 to 521, Akira et al.: "A new neutral-point-clamped PWM inverter"
discloses an inverter wherein a series circuit of two capacitors is connected across
the battery. The connection node between the two capacitors is interconnected with
tabs of the series connected transistors which serve for controlling the excitation
of the U, V and W windings of the AC motor. Thus, a three-level voltage control of
the switches can be achieved.
[0034] It is an object of the present invention to provide an integral type power train
for an electric vehicle, which is small, light, inexpensive, low-noise, and can realize
the traveling performance comparable to that of an internal combustion engine car
except for the mileage.
[0035] In accordance with the present invention, there is provided a power train for an
electric vehicle as defined in claim 1.
[0036] Here, the power converter may comprise the features mentioned in subclaim 2.
[0037] According to the features of subclaim 2, the following advantages can be obtained.
(1) If the first, second, and third levels are determined as V0/2, V0 and 0, where V0 is the battery voltage, the power switching devices having a low withstanding voltage
V0/2 can be employed. This makes it possible to reduce the ON state voltage of the power
switching devices in comparison with a conventional inverter which requires power
switching devices whose withstanding voltage is V0.
(2) Since the power switching devices of the inverter switch a first voltage or the
difference voltage of the first and second voltages (both voltages are typically V0/2) lower than that of a conventional inverter (V0), the switching loss of the power switching devices is reduced, and hence, the loss
of the inverter is also reduced.
(3) Unipolar switching device will further reduce the stationary loss of the switching
devices in a low output power operation mode because the ON state voltage is approximately
directly proportional to the current passing through the power switching devices,
and hence, the stationary loss is approximately directly proportional to the square
of the current.
[0038] The above and other objects, effects, features and advantages of the present invention
will become more apparent from the following description of the embodiments thereof
taken in conjunction with the accompanying drawings.
Fig. 1 is a circuit diagram showing a main circuit of a conventional electric vehicle;
Fig. 2 is a graph illustrating a relationship between the current id and the ON state voltage vd of a bipolar power switching device;
Fig. 3 is a diagram illustrating waveforms at a turn-on operation of a power switching
device of an inverter;
Fig. 4 is a diagram illustrating waveforms at a turn-off operation of a power switching
device of an inverter;
Fig. 5 is a graph illustrating the relationships between the output power of an induction
motor and a motor current, and the output power and a motor voltage;
Fig. 6 is a block diagram showing a power train of a conventional electric vehicle;
Fig. 7 is a block diagram showing another power train of a conventional electric vehicle;
Fig. 8 is a block diagram showing still another power train of a conventional electric
vehicle;
Fig. 9 is a circuit diagram showing an embodiment of an inverter for an electric vehicle;
Fig. 10 is a graph illustrating t-he relationship between the ON state voltage and
the current of a power MOSFET;
Fig. 11 is a diagram illustrating a waveform of the output voltage of the inverter
of Fig. 9 in a high output power operation mode;
Fig. 12 is a diagram illustrating a waveform of the output voltage of the inverter
of Fig. 9 in the intervals [1] and [3] of Fig. 11;
Figs. 13 and 14 are diagrams illustrating the operation of the inverter of Fig. 9
in the intervals [1] and [3];
Fig. 15 is a diagram illustrating a waveform of the output voltage of the inverter
of Fig. 9 in the interval [2] of Fig. 11;
Figs. 16 and 17 are diagrams illustrating the operation of the inverter of Fig. 9
in the interval [2];
Fig. 18 is a diagram illustrating a waveform of the output voltage of the inverter
of Fig. 9 in a low output power operation mode;
Fig. 19 is a block diagram showing the arrangement of an embodiment of a power train
in accordance with the present invention;
Fig. 20 is a perspective view showing the power train of Fig. 19;
Fig. 21 is a block diagram showing the arrangement of another embodiment of a power
train in accordance with the present invention; and
Fig. 22 is a perspective view showing the power train of Fig. 21.
[0039] The invention will now be described with reference to the accompanying drawings.
[0040] Fig. 9 shows an embodiment of an inverter wherein the contents of the V and W phases
of the inverter main circuit is omitted. The arrangement of Fig. 9 corresponds to
the inverter 2 and the smoothing capacitor 4 stated before with reference to Fig.
1, and hence, the entire system can be constructed by connecting the main battery
1 and the motor 3 to the arrangement of Fig. 9.
[0041] In Fig. 9, two capacitors 41 and 42 connected in series constitute a smoothing capacitor
4 which is substantially the same as the smoothing capacitor 4 in Fig. 1.
[0042] Since three inverter arms 21 - 23 have the same construction, only the inverter arm
21 of the U phase is explained here. In the inverter arm 21, four power semiconductor
switching devices 210 - 213, which are unipolar power switching devices such as a
power MOSFET or the like, are connected in series in the same polarization. An AC
output terminal U is provided at the connecting point of the power switching devices
211 and 212 so that the AC output of the U phase is produced from this terminal U.
The power switching device 210 is connected to the positive terminal P of the DC source,
whereas the power switching device 213 is connected to the negative terminal N thereof.
[0043] Current feedback diodes 214 - 217 are connected with the power switching devices
210 - 213 in antiparallel fashion. Diodes 218 and 219 are connected in series as shown
in this figure so that the cathode terminal of the diode 218 is connected to the connecting
point of the power switching devices 210 and 211, whereas the anode terminal of the
diode 219 is connected to the connecting point of the power switching devices 212
and 213. The connecting point of the diodes 218 and 219 are connected to the connecting
point of the capacitors 41 and 42.
[0044] Next, the operation of this embodiment will be described.
[0045] First, Fig. 10 illustrates a voltage-current characteristics of the power MOSFET
used as the power switching devices 210 - 213, which exhibits approximately resistive
characteristics.
[0046] Figs. 11 - 18 illustrate the operation of this embodiment. Fig. 11 shows an output
voltage waveform (the line-to-line voltage waveform) of the inverter during a high
power output (or a high and middle power output). In this figure, the dotted line
indicate the waveform of the fundamental voltage of the motor. To obtain the fundamental
voltage, the following control is achieved: during the intervals [1] and [3] in the
half cycle, the output voltage of the inverter is produced in the form of PWM pulses
whose height is half the main battery voltage V
0/2 and whose base level is zero Volt; on the other hand, during the middle interval
[2] in the half cycle, the output voltage is produced in the form of PWM pulses whose
height is half the main battery voltage V
0/2 and whose base level is half the main battery voltage V
0/2. In other words, the inverter operates as a three-level inverter.
[0047] Figs. 12 - 14 illustrate the operation to obtain the PWM pulses during the intervals
[1] and [3].
[0048] Fig. 12 illustrates the waveform of the output voltage (the line-to-line voltage)
of the inverter wherein A designates the interval during which half the main battery
voltage V
0/2 is outputted, and B denotes the interval during which the voltage is zero.
[0049] Fig. 13 illustrates the operation of the power switching devices of the U - V phases
during the interval A of Fig. 12. In Fig. 13, reference numeral 212(V) designates
the power switching device in the V-phase, which is the counterpart of the power switching
device 212 in the U-phase, and reference numeral 213(V) designates the power switching
device in the V-phase, which is the counterpart of the power switching device 213
in the U-phase.
[0050] During the interval A of Fig. 12, the power switching devices 211, 212(V) and 213(V)
are closed. By this, the voltage across the capacitor 42 (that is, V
0/2) is added between the output terminals U-V via the diode 218. In this state, it
is assumed that the current is flowing in the direction indicated by the arrows in
Fig. 13. Subsequently, when the power switching device 211 is opened, a new current
passage will be established as shown in Fig. 14. The passage passes through the output
terminal V, the power switching device 212(V), the power switching device 213(V),
the diode 217, the diode 216 and the output terminal U so that the voltage between
the output terminals U-V becomes zero as in the interval B of Fig. 12.
[0051] Next, the operation during the interval [2] of Fig. 11 will be described with reference
to Figs. 15 - 17.
[0052] Fig. 15 illustrates the waveform of the output voltage of the inverter (line-to-line
voltage), wherein C designates the interval during which the main battery voltage
V
0 is outputted, and D denotes the interval during which half the main battery voltage
V
0/2 is outputted.
[0053] Fig. 16 illustrates the operation of the power switching devices during the interval
C in a manner similar to Fig. 13 wherein the operation during the interval A is illustrated.
During the interval C, the power switching devices 210, 211, 212(V) and 213(V) are
all closed so that the voltage across the two capacitors 41 and 42 (that is, V
0) is applied between the output terminals U-V. In this state, it is assumed that the
current is flowing as indicated by the arrows of Fig. 16. Subsequently, when the power
switching device 210 is opened, a new current passage is established as shown in Fig.
17: the current flows through the capacitor 42, the diode 218, the power switching
device 211, and the output terminal U so that the voltage across the capacitor 42
(that is, V
0/2) is applied between the output terminals U and V via the diode 218.
[0054] Fig. 18 illustrates the waveform of the output voltage (line-to-line voltage) of
the inverter when the motor is operated in a low output operation mode. The voltage
waveform is a PWM waveform whose height is V
0/2 and whose base level is zero. In this case, since the operation of the power switching
devices of the inverter is similar to that of the intervals [1] and [3] of Fig. 11,
the explanation thereof is omitted here.
[0055] The dotted line shown in Fig. 18 shows a fundamental waveform of the voltage of the
motor whose peak value V
Mm is expressed by the following Equation 3.

The output voltage of the inverter can take a waveform as shown in Fig. 18 in a range
where the motor voltage is smaller than the peak voltage V
Mm.
[0056] Although it is supposed that the motor driven by the inverter is an induction motor
in this embodiment, a synchronous motor can also be applied to the present invention.
[0057] Furthermore, the present invention can be applied not only to three-phase inverters
but also to multi-phase inverters.
[0058] Next, preferred examples of the power train in accordance with the present invention
will be described below.
[0059] Fig. 19 is a first example of a power train which integrates a semiconductor power
converter, a motor and a differential gear into a unit. Here, the semiconductor power
converter comprises an inverter as described above, and the differential gear is provided
with a reduction function. Driving of wheels is accomplished by driving the motor
by the power converter, and by transmitting the power of the motor to the right and
left wheels via the differential gear having the reduction function.
[0060] More specifically, in Fig. 19, a driving unit 100 integrally incorporating the power
train comprises a power converter 101, a motor 3 and a differential gear 103 having
a reduction function.
[0061] The motor 3 is an AC motor whose output shaft is joined to the input shaft of the
differential gear 103. The power converter 101 comprises the inverter described above.
The inverter incorporates its controller.
[0062] The power converter 101 is connected to the motor 3 by directly connecting their
terminals with each other, or by connecting the terminals with shortest wires in the
driving unit 100.
[0063] The differential gear 103 is similar to a differential gear employed by a conventional
electric vehicle except that the differential gear 103 has a greater reduction gear
ratio than the conventional one so that it is provided with a reduction function.
The output shaft of the differential gear 103 is joined to the right and left wheels
61 and 62 via the wheel axles 71 and 72 so that they drive the wheels 61 and 62.
[0064] Fig. 20 is a perspective view of the driving unit 100. A portion of a casing of the
differential gear 103 is made a mounting portion A on which a unit integrally incorporating
the power converter 101 and the motor 3 in a frame made of metal is mounted. Thus,
the integral structure comprising the power converter 101, the motor 3 and the differential
gear 103 constitutes the driving unit 100. The output shaft 86 of the motor 3 is joined
to the input shaft of the differential gear 103 inside the casing.
[0065] Fig. 21 is a second example of the power train in accordance with the present invention,
which comprises a reduction gear 104 in the driving unit in the case where the reduction
gear ratio of the reduction gear 103 in the power train of Fig. 19 is insufficient.
[0066] In other words, the power train of Fig. 21 comprises a semiconductor power converter
including the inverter described above a motor, a reduction gear, and a differential
gear, which are constructed into an integral structure.
[0067] More specifically, as shown in Fig. 22, the power converter 101, the motor 3 and
the reduction gear 104 are integrally mounted on the mounting portion A provided on
a part of a casing of a differential gear 103'. All these components are arranged
into an integral structure to constitute a driving unit 100' as shown in Fig. 22.
Here, the output shaft of the motor 3 is joined to the input shaft of the reduction
gear 104 inside the casing. Likewise, the output shaft 87 of the reduction gear 104
is joined to the input shaft of the differential gear 103' inside the casing.
[0068] The power trains as shown in Figs. 19 and 22 are formed as a driving unit which incorporates
the power train of an electric vehicle into an integral structure. Thus, a small,
light, low cost power train can be implemented.
[0069] In addition, since the power converter like an inverter, and the motor are integrated,
they can share a cooling device so that the cooling system can be simplified, thereby
resulting in further reduction in cost and the improvement in efficiency. Further,
since the wires connecting the power converter to the motor as the AC connecting wires
can be obviated or made shortest, electromagnetic faults caused by noise generated
by the connecting wires are remarkably reduced.
[0070] Moreover, since the electric leads pulled out of the casing consist of only DC connecting
wires, and all the components of the driving unit can be covered by the casing made
of metal, the electromagnetic faults caused by these components will be greatly reduced.
[0071] In addition, the power train, the power converter and the motor control system can
be simplified in comparison with the conventional systems as shown in Figs. 7 and
8 wherein each wheel is separately driven because all the power trains of the present
invention comprise the differential gear. Moreover, a steering performance similar
to that of an internal combustion engine car can be obtained.